How to Cut Plexiglas for Windows

Plexiglas is a form of acrylic and is used by homeowners and hobbyists alike in many different applications from motorcycle windshields to windows. It is possible to cut your own windows out of Plexiglas if you know what to do and use the right tools. Plexiglas is flexible and comes in different thicknesses. When cutting this material, you must take care to use the right-size saw blade; otherwise, you risk having the saw blade heat up and melt the Plexiglas.

Things You'll Need

• Masking tape
• Grease pencil
• Poster board
• Safety goggles
• Power saw or table saw
• Saw blade
• 220-grit sandpaper

Instructions

1. Cover both sides of the Plexiglas with masking tape over the section where the cuts will be made. This prevents the Plexiglas from chipping while it's being cut. Do not remove the protective paper that covers the Plexiglas until the window is cut and the sides are sanded.

2. Measure the area for your Plexiglas window and then transfer those measurements with a grease pencil to the sheet of Plexiglas. Use a carpenter's square to make sure the lines are straight and the corners are perfect. If the window has any curves, make a template from poster board. Lay the pattern on the Plexiglas and draw around it, using a grease pencil.

3. Equip a power saw or table saw with the correct blade, depending on the thickness of the Plexiglas. A thick sheet of Plexiglas needs a blade that has fewer teeth, and for a thin sheet of Plexiglas, use a fine-toothed saw blade. Talk to the clerk at the store when you purchase the Plexiglas to determine which blade will work the best; otherwise, you risk melting the edges of the Plexiglas.

4. Cut the Plexiglas. Saw through the material slowly and carefully.

5. Sand the edges with 200-grit sandpaper. This removes any of the rough edges. When you're finished, remove the masking tape from the Plexiglas and install the window where needed.

Tips & Warnings

• Wear safety goggles to protect your eyes when you cut the Plexiglas.

References

• Plexiglass Info: Cutting Plexiglass
• Plexiglass Info: Plexiglass Cutting Tools
• Bowers Fly Baby: Fly Baby Windshields
• "Plexi Class: Cutting-Edge Projects in Plastic"; Tonia Davenport; 2008